CT&F Ciencia, Tecnología y Futuro

ISSN: 0122-5383
ctyf@ecopetrol.com.co
ECOPETROL S.A.
Colombia

López, Diana-C.; Mahecha, Cesar-A.; Hoyos, Luis-J.; Acevedo, Leonardo; Villamizar, Jaime-F.
Optimization model of a system of crude oil distillation units with heat integration and metamodeling
CT&F Ciencia, Tecnología y Futuro, vol. 3, núm. 5, diciembre, 2009, pp. 159-173
ECOPETROL S.A.
Bucaramanga, Colombia

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 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING

Ciencia, Tecnología y Futuro

OPTIMIZATION MODEL
OF A SYSTEM OF CRUDE OIL
DISTILLATION UNITS WITH
HEAT INTEGRATION AND
METAMODELING

Diana-C. López1, Cesar-A. Mahecha2*, Luis-J. Hoyos2, Leonardo Acevedo3 and Jaime-F. Villamizar3

1
Convenio Ecopetrol S.A. - Instituto Colombiano del Petróleo - Universidad Industrial de Santander (UIS), Bucaramanga,
Santander, Colombia
2
Ecopetrol S.A. - Instituto Colombiano del Petróleo, A.A. 4185 Bucaramanga, Santander, Colombia
3
Universidad Industrial de Santander (UIS), Escuela de Ingeniería Química, Bucaramanga, Santander, Colombia

e-mail: cesar.mahecha@ecopetrol.com.co e-mail: dianaca.lopez@ecopetrol.com.co

(Received March 3, 2009; Accepted October 29, 2009)

T he process of crude distillation impacts the economy of any refinery in a considerable manner. Therefore, it is
necessary to improve it taking good advantage of the available infrastructure, generating products that conform
to the specifications without violating the equipment operating constraints or plant restrictions at industrial units.
The objective of this paper is to present the development of an optimization model for a Crude Distillation Unit (CDU)
system at a ECOPETROL S.A. refinery in Barrancabermeja, involving the typical restrictions (flow according to pipeline
capacity, pumps, distillation columns, etc) and a restriction that has not been included in bibliographic reports for this
type of models: the heat integration of streams from Atmospheric Distillation Towers (ADTs) and Vacuum Distillation
Towers (VDT) with the heat exchanger networks for crude pre-heating. On the other hand, ADTs were modeled with
Metamodels in function of column temperatures and pressures, pumparounds flows and return temperatures, stripping
steam flows, Jet EBP ASTM D-86 and Diesel EBP ASTM D-86. Pre-heating trains were modeled with mass and energy
balances, and design equation of each heat exchanger. The optimization model is NLP, maximizing the system profit.
This model was implemented in GAMSide 22,2 using the CONOPT solver and it found new operating points with bet-
ter economic results than those obtained with the normal operation in the real plants. It predicted optimum operation
conditions of 3 ADTs for constant composition crude and calculated the yields and properties of atmospheric products,
additional to temperatures and duties of 27 Crude Oil exchangers.

Keywords: crude distillation units system, CDU, optimization, NLP, metamodels, operational constraints, energy constraints
(restrictions), heat exchanger network.

* To whom correspondence may be addressed

CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009 159

 DIANA-C. LÓPEZ et al.

L
a destilación de crudo es un proceso que impacta considerablemente la economía de cualquier
refinería y por tanto es necesario mejorarlo aprovechando la infraestructura instalada, generando
productos dentro de especificaciones, sin violar las diferentes ventanas operativas o restricciones
de planta que existen en las unidades industriales. El objetivo de este artículo es presentar el desarrollo de
un modelo de optimización de un Sistema de Unidades de Destilación de Crudo (UDCs) perteneciente a
la refinería de Barrancabermeja de ECOPETROL S.A. que involucra las restricciones de planta típicas (flujo
por capacidad de tuberías, bombas, torres de destilación, etc.) y una restricción aún no contemplada en la
literatura para modelos de este tipo: la integración energética de las corrientes de las Torres de Destilación
Atmosféricas (TDAs) y las Torres de Destilación al Vacío (TDVs) con la red de intercambiadores de calor
que precalientan el crudo. Por otro lado, las TDAs fueron modeladas a través de Metamodelos en función
de las temperaturas y presiones de las torres, los flujos y temperaturas de retorno de los pumparounds, los
flujos de vapor de despojo, el PFE de la ASTM D-86 para el Jet y el Diesel. Los trenes de precalentamiento
fueron modelados con balances de masa y energía, y la ecuación de diseño de cada intercambiador. El
modelo de optimización es de tipo NLP, maximizando la utilidad del sistema. Este modelo se implementó
en GAMSide 22.2 usando el solver CONOPT y predice nuevos puntos de operación óptimos con mejores
resultados económicos que aquellos obtenidos con la operación normal en las plantas reales. El modelo
calculó las condiciones de operación óptimas de 3 TDAs para un crudo de composición constante y calculó
los rendimientos y propiedades de los productos atmosféricos, adicionalmente a las temperaturas y duties
de 27 intercambiadores de crudo.

Palabras Clave: sistema de unidades de destilación de crudo, UDC optimización, PNL, metamodelos, restricciones
operacionales, restricción energética, red de intercambiadores de calor.

160 CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009

 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING
INTRODUCTION
Crude Distillation Units are key process plants
in a petroleum refinery as they produce intermediate
streams that are used in downstream process units.
Changes in these units have a great impact on product
yield and quality and, therefore, it is recommended to
operate these units at optimal conditions from technical
and economical points of view; that means operating
conditions such as temperatures, pressures and flows
of the units that maximize their economic performance
(increasing product yield), subject to their real physical
restrictions and their design capabilities. Mathematical
modelling has become very common to develop these
optimization studies.
There are several strategies that can be used to per-
form mathematical optimization processes. Linear Pro-
gramming (LP) is generally used in production planning
and programming due to their simplicity. However, its
precision has been the subject of discussion for decades
due to the simplified linear formulation of non-linear
processes that can lead to non real solutions. These li-
near models usually do not consider interactions among
CDUs occurring when these units share pre-heating
sections or exchange streams among them (Wenkai,
Chi-Wai, & AnXue, 2005), (Zhang, Zhu, & Towler,
2000, 2001). One of the most important strengths of
linear models is that they always converge in reaso-
nable calculation times. Another optimization strategy
consists in the utilization of rigorous models, based
on thermodynamic principles linked to an optimizer
(Basak, 2002). Even though this type of optimization
begins with a precise CDU representation, it exhibits
serious problems for its practical implementation since
it does not ensure convergence and the calculation
time increases significantly for very complex models.
Furthermore, synchronization problems might occur
when the model and the optimizer do not use the same
platform. In refinery planning, using rigorous process
models entails serious complications because these
models require long solution times and frequently
hide critical characteristics and parameters in order to
increase profits (Hartmann, 2001).
There are other optimization strategies combining
LP models with rigorous models, as it is reported by
CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009
Zhang (2000), who independently performs non-linear
optimization of each process, such as CDUs, in order
to minimize operation costs by using fixed information
from the LP model results. Due to the deficiencies in
the above mentioned strategy, Zhang (2000) proposes an
alternative where process optimization results are com-
pared to the results from LP model. If they match with
each other and do not violate any equipment operating
constraints, implementation of these results is considered
feasible. If this is not the case, process level results are
used to feedback and update production yields of units
in the LP model. This is a cyclic procedure that might
take long execution times when using optimization with
rigorous process models.
Furthermore, Zhang (2001) proposes another strategy
in order to take advantage of synergy among processes.
The idea applies again the LP model structure, although
this time proposes the inclusion of non-linear process
models within the global model through linearization
techniques. As a consequence, representation capabi-
lity of each unit within the global model improves. This
concept was implemented in some commercial software
such as Aspen-PIMS, thus creating an evolution of such
programs.
The last strategy mentioned here was proposed by
the Brazilian researchers (Pinto, Joly & Moro, 2000)
who have shown their interest in the improvement of
planning models by enhancing process representation
using non-linear optimization. They propose the inclu-
sion of process complexity within the model, in order
to improve the accuracy of the results. In other words,
they consider the non-linear representation of units such
as CDU within the macromodel in order to take advan-
tage of the interaction among processes and provide
operational guidelines to the units through a simple but
robust model.
This paper describes a new strategy based on meta-
modelling to optimize complex systems and presents the
simultaneous optimization of three crude oil distillation
towers with their heat integration (crude oil preheating
trains) as an example of application. Metamodels are
approximated models from rigorous simulation that
can be used on a routine basis due to their quick imple-
161
 DIANA-C. LÓPEZ et al.
mentation, execution, and convergence, surpassing the
rigorous models (Palmer & Realff, 2002a and 2002b).
Crude oil preheating trains were represented by rigo-
rous exchanger models. Metamodels were developed
from previous PRO/II rigorous models of the industrial
units. Metamodels of the distillation towers and rigorous
models of the heat exchange trains were integrated in
the GAMSide 22.2 - based optimization algorithm that
maximizes the CDU system profits, finding optimum
operation conditions for each atmospheric distillation
tower.
METHODOLOGY
The system to optimize comprises three crude oil
distillation units (CDU1, CDU2 and CDU3) and these
crude units are composed by three atmospheric distilla-
tion towers with different design characteristics (ADT1,
ADT2 and ADT3), three atmospheric furnaces (AF1,
AF2 and AF3), two vacuum towers (VDT1 and VDT2)
and two heat exchanger networks (NET1 and NET2).
Figure 1 shows a simplified diagram of the CDUs studied
in this work.
CDU 1
NET1
AF1
ADT2
AF 2
Figure 1. Simplified diagram of the Crude Distillation Unit System
162
CDU1 and CDU2 share the network NET1 con-
formed by 17 exchangers and the NET2 is composed
of 10 heat exchangers. The vacuum residue stream from
CDU3 interacts with CDU2 through the NET1 network
preheating the Crude Oil that feeds this unit.
PRO/II Model Construction
A rigorous model using the commercial simulator
PRO/II ® version 8.0 was constructed for each CDU.
As thermodynamic packages, the Grayson-Streed and
Braun K10 (BK10) equations of state were used in the
atmospheric and vacuum towers respectively. Feedstock
stream was characterized using the TBP curve, API grav-
ity curves, sulfur content, neutralization number (NN),
Conradson Carbon content (CCR) and lightends content
(C1, C2, C3, iC4, nC4, iC5, nC5, hexane, H2O, CO2, CO,
N2 and H2). PRO/II models were tuned with the infor-
mation from industrial runs. Regarding ADTs, the set of
manipulated variables is conformed by the ope-ration
variables (Crude flow, input and output furnace tempera-
tures, temperature and pressure on the top of the column,
pumparounds flows and return temperatures, stripping
steam flows, condenser temperature and pressure). A
quality control variable of the JET and DIESEL products
is also included: End Boiling Point (EBP) ASTM D-86
distillation curve.
CDU 3
ADT 3
ADT 1
NET2
VDT 1
AF 3
VDT 2
CRUDO OIL
CDU 2 NAPHTHA AGO
JET REDC
DIESEL VACUUM
RESIDUE
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 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING

Construction of Atmospheric Tower Metamodels The input variables set is composed for the PRO/II
For the purpose of this research, non-linear semi- manipulated variables and changes depending on the
rigorous models (Metamodels) of each atmospheric design of the tower (see Table 1).
tower were constructed. The methodology used to
develop the Metamodels includes:1) Selection of input The data collection plan or Design of Experiments
variables, 2) Design of Experiments (Latin Hypercube), (DoE) used was the sampling process by Latin Hypercube
3) Generation of data using PRO/II models, 4) Parame- (LHS: Latin Hypercube Sample) which provides unique
trization of Metamodels using multivariate stepwise values for each point and exhibits better dispersion than
regression, 5) Validation and evaluation of their sig- other sampling procedures such as the random and grid
nificance. Output variables in Metamodels were flows, sampling (Palmer & Realff, 2002a and 2002b).
temperatures, and properties of all the streams leaving
the towers (products and pumparounds toward NET1
The Metamodels were a second-order polynomial
and NET2). The properties calculated by Metamodels
function with binary interaction:
were API gravity, ASTM D-86 curve (10, 30, 50, 70
and 90%) and calorific capacities. Pumparound duty
Metamodels of ADT1, ADT2 and ADT3 were created,
which were linked to the NET1 and NET2.

Table 1. Metamodels Input Variables of ADT1 and ADT2

CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009 163

 DIANA-C. LÓPEZ et al.

Where ŷ(X) was the output variable vector (flows, analysis were used for the detection outliers within the
temperatures, properties, etc.), X is the normalized input Metamodel construction set. In order to measure the
variable vector, (feed flow, operating conditions, and Metamodel prediction capability, the R2Prediction (Mont-
quality properties) with i=1,..,13 for ADT1, i=1,..,138, gomery, 2001) was calculated. Each metamodel was
for ADT2 and i=1,..,17 for ADT3. Each output varia- evaluated by a validation set with 1.000 simulated points
ble has a Metamodel with characteristic parameters in PRO/II to verify their prediction quality before using
according to its behavior in regards to the input varia- them in the optimization model. Figure 2a shows the
bles. For ADT1, 105 parameters were calculated; for correlations between calculated volumetric flow for the
ADT2, 190 parameters and for ADT3, 171 parameters ADT2 products with Metamodels and the results found
were found. in PRO/II. Figure 2b shows the error distribution of
product flow Metamodels for ADT1 and ADT2.
Furthermore, 5000 sampling points were used in
Metamodels construction (N=5000). These points Atmospheric tower Metamodels showed a maxi-
represented 5000 simulation runs for each distillation mum average error of 2,5% with a standard deviation
tower (ADT1, ADT2 and ADT3) using the configured of 0,41% for flows, while for the rest of the properties
and tuned rigorous models in PRO/II. Due to the random the maximum average error was 2,0% with standard
nature of LHS for each independent variable and to deviation of 0,75%.
the complexity of the distillation process, 100% con-
vergence of the model is not attained. Therefore, only Construction of Heat Exchanger Integrated Networks
converged data was used in Metamodels construction.
NET1 and NET2 of the CDU system were modeled
through energy balances by Equation 2 on the hot side,
Parameters for each Metamodel were estimated by Equation 3 on the cold side and by the design equa-
based on the matrix of experimentation results in PRO/ tion expressed in Equation 4.
II, using multivariate stepwise regression. During re-
gression, input variables were normalized between -1
and 1, and output variable results (ŷ(x) were in the real
magnitude corresponding to each variable.

A typical residual analysis, an escalated residual

analysis (standardized and studentized) and a PRESS

35.000
DIESEL AGO GOA REDC 5
30.000
y = 0,9659x + 271,34 y = 1,0021x - 1,8966 y = 1,0016x - 33,274
NAPHTA-ADT1 JET-ADT1 DIESEL-ADT1
25.000 R2 = 0,967 R2 = 0,9996 R 4
NAPHTA-ADT2 JET-ADT2 DIESEL-ADT2
Metamodels

20.000
3
Error (%)

15.000

10.000 NAPHTA
NAFTA JETJET 2
y = 1,0015x - 9,7902 y = 0,9714x + 160
5.000 1
R2 = 0,9999 R2 = 0,9623
0
0 5.000 10.000 15.000 20.000 25.000 30.000 35.000 0
NAPHTA-ADT2 JET-ADT2 DIESEL-ADT2 0 150 300 450 600
PRO/II AGO-ADT2 REDC-ADT2 Identity Experiments

a) b)

Figure 2. Flow Metamodel (bl/d) in a validation set: a) Metamodels and PRO/II Correlations. b) Errors (%)

164 CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009

 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING
Qhx,u is the duty of the hx exchanger belonging to the
set of exchangers corresponding to the CDU, u belon-
ging to the U set (CDU1, CDU2 and CDU3). Fh,hx,u is the
mass flow of hot stream (h), entering the hx exchanger,
of the unit u. Th_in,hx,u is the input temperature (in) of
h that enters the hx exchanger of the unit u. Th_out,hx,u
is the output temperature (out) of h that enters the hx
exchanger of unit u. The same naming system is used
for the cold fluid (c). Uhx,u y Ahx,u are global heat transfer
coefficient (BTU/day ft2 °F) and transfer area in ft2 (see
Table 3) of exchanger hx belonging to unit u.
The values for h and c in Equation 5 were
determined by correlations (API Technical Data Book,
2005) in function of mean input temperature to the ex-
changer of c and h ( ) and the constants A1, A2 and
A3 (functions of the ASTM D-86 curve, Watson factor
and Specific Gravity of each stream).
Table 2. Flow Plant Restrictions of Products Pumping and Furnace Duties Plant Restrictions
The path flow of each fluid through the whole set of
exchangers was considered in network configuration,
including recycles and bypass from real plants.
Determination of CDUs Operating Constraints
There are different operating constraints within an
CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009
industrial plant that ensure equipment integrity. In the
optimization model, flow restrictions were included
based on pump capacity, input and output temperature
restrictions of exchangers to ensure their useful life,
and restrictions at furnace duties (Tables 2 and 3). As
product quality restrictions for JET and Diesel, maxi-
mum EBP values of 570ºF and 760ºF were considered
respectively.
Identification of the Optimization Model Objective
The objective of the optimization model was maxi-
mize the CDU system profit (Pr) that considers distilla-
tion towers, furnaces, and heat integration as operating
restriction for a Crude feedstock with constant compo-
sition. Pr of the CDU system is defined as the income
due to the sale of products, minus the raw material costs,
minus the operating cost for each CDU:
C F 
CF 
vol vol vol
Pr C F s,t s,t t t r,t t (6)
t Ua s Pa t Pa t Ua r R
The income due to product sale is defined in Pa
for all products. This is the set of atmospheric pro-
ducts (Naphtha, Jet, Diesel, AGO, and Reduced Crude
-REDC) from all the atmospheric towers Ua (ADT1,
ADT2 and ADT3). The raw material cost is defined for
all crudes entering to each atmospheric tower Ua. The
operation cost is defined considering all the resources
consumed in the process, R, such as fuel, compressed air,
fresh water, industrial water, steam and electricity.
165
 DIANA-C. LÓPEZ et al.

Table 3. Plant Restrictions of Crude Oil Preheating Exchangers: Temperatures and Areas

Table 4. Feed and Product Prices of an Table 5. Operation Cost of Crude Distillation Units (US$/bl of feedstock)
Atmospheric Tower (US$/bl)

STREAM PRICE
CRUDE 36,2
NAPHTHA 76,6
JET 91,5
DIESEL 89,6
AGO 20,0
REDC 15,0
Source : Refinery Global Model 2001 -ECOPETROL S.A.

The stream price data and the operation costs in

dollars per barrel (US$/bl) are listed in Tables 4 and 5, Selection of Solver in GAMS and Initial Point
respectively. The manipulated variables in maximization Non-linear models created with GAMSide version
were the Metamodel input variables shown in Table 1. 22,2 (Brooke, Kendrick, & Meeraus,1992) must be

166 CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009

 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING
solved with Non-Linear Programming algorithms (NLP).
This research used the CONOPT solver since it correctly
manages correctly models with many non-linear restric-
tions and a moderate number of degrees of freedom. These
are characteristics of the problem analyzed here. The
Initial Estimation (IE) was a set of operating conditions
close to an operation of the industrial unit. Therefore, an
operation with low yield of REDC and maximum Jet or
Diesel production were selected.
Running the Optimization Model and Results
Once the objective function and the model restrictions
were configured, and the solver in GAMS was specified,
the next step was to solve the optimization problem. The
results of the model included the profit of the system and
of each CDU. Regarding ADT1, ADT2 y ADT3, they
included: operating variables, Crude flow, products yields,
flow, temperatures and properties of both products and
pumparounds. The following is included for NET1 and
NET2: Duties, temperatures and properties of Crude and
hot streams at the entry and exit of each exchanger. The
furnace duty was calculated.
Simulation of the Optimum Point Generated by
GAMS
An algorithm is designed to find the feasible optimum
point (Figure 3). This algorithm contemplates n simu-
lations in PRO/II, including the first run to find the IE
of optimizer and n-1 optimization runs in the GAMS
Simulate= 1,..,n;Optimize=1,..,n-1
Plant runs and / or converged points in PROII
Operation and Quality variables
Simulate= 0; Optimize=0
RIGOROUS MODELS IN PRO/II
Simulate=Simulate + 1
Inicial Estimation Variables: VIE
Operation and Quality Variables

Temperatures of Crude Oil Exchangers
CDU METAMODEL OPTIMIZER
Optimize=Optimize + 1
Optimum Variables: VOpt
Operation and Quality Variables
Optimum –Feasible:
NO YES Operation and
|Vopt- VIE|<TOL
Quality Variables
Figure 3. Algorithm to find the Feasible Optimum Point
CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009
model that generates the operational and quality condi-
tions called the Optimum Feasible Point.
The algorithm in Figure 3 starts from available runs plants
in CDUs and/or converged points of individual models
in PRO/II of ADT1, ADT2 and ADT3 such as IE, which
enters the CDU metamodel optimizer in GAMS. Next
the run is completed and the Optimum Variables (Vopt) are
obtained; and they are compared to the Initial Estimation
Variables (VIE). The cycle finishes when these values are
close enough to each other (<TOL).
Optimum Point Sensitivity Analysis
Due to the fact that it is a NLP optimization, the new
operational point found by GAMS is a local optimum
point. Several IE were tested in order to figure out the
contour of the objective function. The optimum points
were compared and the best one was selected as the most
profitable of the system.
MATHEMATICAL MODEL OPTIMIZATION
An optimization of the model, maximizing Pr in
Equation 6, was developed. This model was subject to
semi-rigorous process models (Metamodels), restrictions
such as pro-duct specifications, operational variable
boundaries, limits of other equipments and the energy
of the pre-heating crude trains. The objective function
of Equation 6 is subjected to mass balances on each
tower such as in Equation 7, to upper and lower limits
of feed flow to the towers of Equation 8, to boundaries
of operation and quality variables of Equations 9 and
10, to restrictions of products and pumparounds flow ac-
cording to pump capacity of Equations 11 and 12, to the
maximum operation limits of duties of the atmospheric
furnaces in Equation 13, to the maximum limit of the
fluid temperature h entering the exchangers in Equation
14 and the c fluid coming out the exchangers in Equation
15, to the set of equations representing the networks NET
1 and NET2 of Equations 2, 3, 4 and 5 and, of course, to
the process model using Metamodels.
167
 DIANA-C. LÓPEZ et al.
The L and U superscripts indicate the lower and upper
level that can take the flow or involved variables. The
Operation Variables (Vopt) of the atmospheric tower t, are
independent variables inside PRO/II and their amount
depends on tower design. Quality variables (Vqs) included
are the EBP of ASTM D-86 for Jet and Diesel. Qf,t is the
furnace duty, f, belonging to t.
The ADT typical model is represented by Equations
16 and 17.
-Total flow of each product stream:
-Property of each product stream:
The function Øs,t is the Metamodel that calculates
flow of product s, of tower t. The function χp,s,t is
the Metamodel that calculated the property p of the
products of the tower t. API gravity, temperatures of
ASTM D-86 (10, 30, 50, 70, 90%) and Cp are included
among the p properties. All Metamodels follow the
form of Equation (1).
Besides the typical output variables for an ADT
(Equations 16 and 17), Metamodels were constructed
168
to predict the stream temperature leaving the towers,
using Equation 18 for both products and pumparounds
(alternate sub indexes a/s). Furthermore, Metamodels
were constructed for the pumparound duties using Equa-
tion 19 which linked to the networks NET1 and NET2
through Equation 20, depending on the design of each
CDU. Equation 21 is the Metamodel of the atmospheric
furnaces duty.
Q
Qpa,t 
hx Hxpa
hx,u
(20)
The function ηs/pa,t is the Metamodel of temperature
of flows (s if it is a product and pa if it is a pumparound)
exiting tower t. The function μpa,t is the Metamodel of
the pumparound duty pa, either UPA, MPA or LPA be-
longing to the tower t. In Equation (20), the addition of
the network duties is conducted on the set of exchangers
belonging to the HXpa pumparounds. The function ξf,t is
the Metamodel that calculates the atmospheric furnace
duty f of tower t.
RESULTS
The optimization model was formulated in GAMS
(Brooke, 1992) containing 3.881 variables, 3.834 equa-
tions and 9.833 non-linearity, non zeroes. This model
was solved with CONOPT for NLP with a total amount
of time between 16 and 32 seconds, depending on the
closeness of the initial estimation to the optimum value.
The optimization results were compared to the current
CDU situation, where operational conditions are deter-
mined based on plant engineering heuristics, according
to the type of crude to be processed. Considering the
operational and quality restrictions as well as the energy
CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009
 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING

Table 6. optimum operation conditions of the CDU system.

CT&F - Ciencia, Tecnología y Futuro - Vol. 3 Núm. 5 Dic. 2009 169

170
Table 7. Optimum Volumetric Yields of Products of the CDU system

EI-1 EI-2 Optimum IE-1 Optimum IE-2

Variable
ADT1 ADT2 ADT3 ADT1 ADT2 ADT3 ADT1 ADT2 ADT3 ADT1 ADT2 ADT3
NAPHTHA 11,6% 12,7% 10,6% 12,2% 15,1% 10,6% 10,3% 13,0% 19,3% 10,2% 13,0% 20,2%
JET 12,6% 13,1% 11,9% 14,8% 12,4% 11,9% 13,8% 7,8% 13,9% 14,0% 10,9% 12,4%
DIESEL 21,9% 18,7% 16,8% 21,9% 20,8% 16,.8% 25,8% 29,6% 20,5% 25,5% 26,3% 22,6%
DIANA-C. LÓPEZ et al.

AGO 3,8% 2,4% 1,8% 2,1% 1,8% 1,8% 4,0% 1,8% 1,0% 3,9% 1,8% 1,1%
REDC 49,8% 53,2% 58,4% 49,1% 49,9% 58,4% 46,1% 47,8% 44,8% 46,4% 48,0% 43,2%

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Dic. 2009
 OPTIMIZATION MODEL OF A SYSTEM OF CRUDE OIL DISTILLATION UNITS WITH HEAT INTEGRATION AND METAMODELING

exchange within and between CDUs, and the initial es-
timation, the algorithm could predict a new operational
point with better economic results than those obtained
with the normal operation. The summary of the main
optimum operational conditions of the CDU system for
two initial estimations are shown in Table 6.
The product yields are listed in Table 7. The initial
estimation 1 (IE-1) is a typical operational point of real
plant, and the initial estimation 2 (IE-2) is a converged
simulation point in PRO/II. The results of Tables 6-8
were obtained after applying the algorithm described in
Figure 2. Therefore, these constitute feasible optimum
points (with convergence in PRO/II).
Table 8 shows the system profit (Pr) before and after
optimization. The optimum point from EI-1 shows grea-
ter profit than the value found by IE-2, with an increase
of 4,4%. The optimum results from EI-1 of Tables 6-8
represent an increment in the system profit of about two
hundred million dollars (M US$ 200) per year without
modifications in installed infrastructure, only changing
operational conditions and Crude Oil Total Flow.
Table 8. Optimization profits of the CDU system (US$/day)
IE-1 Optimum EI-1 IE-2 Optimum EI-2
1.194.722 1.751.742 1.224.251 1.697.415
Figure 4 shows the ASTM-D86 distillation curves
found in GAMS and validated in PRO/II of some atmos-
pheric products for the CDU system, later optimized by
IE-1. These results are evidence of good Metamodels
prediction within the optimization model.

1.600

1.400

1.200

1.000
Temperature (°F)

800

600

400

200

0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% Recuperated

Diesel ADT1 GAMS Diesel ADT2 GAMS Diesel ADT3 GAMS REDC ADT1 GAMS REDC ADT2 GAMS
REDC ADT3 GAMS JET ADT1 GAMS JET ADT2 GAMS JET ADT3 GAMS Diesel ADT1 PRO/II
Diesel ADT2 PRO/II Diesel ADT3 PRO/II Jet ADT1 PRO/II Jet ADT2 PRO/II Jet ADT3 PRO/II
REDC ADT1 PRO/II REDC ADT2 PRO/II REDC ADT3 PRO/II

Figure 4. ASTM D-86 Distillation Curve of Atmospheric

Products with GAMS and PRO/II

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 DIANA-C. LÓPEZ et al.
CONCLUSIONS
● A new NLP optimization model was proposed for
a CDU system that includes the energy restriction
of plants and utilizes the metamodel approach to
represent the non-linear phenomenon of distillation.
The NLP model maximizes the system profit finding
the optimum operational conditions for each atmos-
pheric tower, calculating products yields and their
properties, temperatures and duties of exchangers
responsible for crude pre-heating.
● The proposed model included satisfactorily the heat
integration of industrial plants as a process restriction
without convergence problems by the Metamodels,
obtaining feasible optimums in PRO/II spending less
time finding the solution.
● The use of Metamodels in this optimization proves
the qualities of this modeling since they represented
the rigorous distillation phenomenon through a sim-
ple function (second degree polynomial), without the
convergence and coupling problems characteristic of
rigorous simulation models offered by commercial
packages. These benefits place them as candidates to
be the predictive tools within more complex models
such as refinery planning that require the representation
of plant reality, thus overcoming the simplified predic-
tions from the LP models used on a routine basis.
● The execution time used by GAMSide to find the
solution was between 16 and 32 seconds. This is a
low value for a problem modeling plant behavior in
a semi-rigorous manner.
● The existence of exchangers in the model of CDU sys-
tem moves the optimum value to different operational
regions from the conditions found if only towers were
used, since they add new restrictions to the problem,
ensuring safe operation within industrial plants.
● The profit increment of the system without investment
and modifications in infrastructure contemplated in
this study, demonstrates the importance of optimiza-
tion models in industrial plants. However, optimization
still has the feedstock fixed (constant composition) to
the units, an aspect that determines the plant operation.
172
Therefore, the feedstock composition is suggested
to be included within operational optimization with
heat integration as an optimization variable within
an unique model.
ACKNOWLEDGMENTS
The authors express their gratitude to ECOPETROL
-ICP, which provided the necessary information for the
development of this study and for the construction and
tuning of PRO/II models.
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